Partsbook Juki APW-297&298 EM

1

1. SPECIFICATIONS

< APW-297>(1) MECAHNICAL SPECIFICATIONS1) Sewing machine : LH-597 model of 2-needle, lockstitch machine with a center knife

(exclusively used for APW)2) Sewing speed : 3,000 rpm (max.)3) Stitch length : Lockstitch : 2.0 to 3.4 mm (standard: 2.5mm)

Condensation stitch : 0.5 to 1.5 mm (standard : 1.0 mm)Back tack stitch : 0.5 to 3.4 mm (Standard : 2.0 mm)Condensation/Back tack stitch selectable

4) Types of welt : Parallel double welt, parallel single welt } Each with flap or without flap5) Pocket lip length : Possible to set in increments of l mm within the range of 18 mm (min.) to

180 mm (max.)Note that the pocket lip length is 25 mm at the minimum when using thecorner knife.For the longer type (option), the maximum sewing length will be 220 mm.

6) Welting width : 10, 12 and 14 mm(needle gauge)

7) Needles : ORGAN Mt 190 #16 to #18 (standard #16)SCHMETZ 190R #100 to #110 (standard #100)

8) Thread : Spun thread #50 (Recommended)9) Hook : Full rotary, vertical-axis, self-lubrication hook

10) Thread take-up lever : Slide thread take-up lever11) Needle bar stroke : 34.4 mm12) Cloth feed mechanism: Driven by servomotor13) Control : By a micro-computer14) Safety mechanism : Machine operation is automatically stopped if the cloth feed mechanism

error detector and, the needle thread breakage detector or any of the varioussafety devices are actuated.

15) Lubricating oil : JUKI New Defrix Oil No.216) Operating air pressure : 0.5 MPa17) Air consumption : Approx. 40 NR/min.18) Dimensions of the machine: 980 mm (width) 1,650 mm (length) 1,200 mm (height)

(1,580 mm when including the stacker)(1,500 mm when including the thread stand)

19) Weight : Approx. 380 kg

(2) ELECTRICAL SPECIFICATIONSOnce the required data is set by means of a built-in micro-computer, the data can be stored in memory (for100 hours) using a built-in battery even after turning OFF the power to the machine unless the setting iscanceled. In addition, the stored data can be output to a personal computer and saved by making use ofthe exclusive circuit board. Further, these data can be copied to the other machines. Consult our JUKIservice man if necessary.

1) The number of patterns that can be stored in memory : 100 (0 - 99)2) The number of cycles that can be stored in memory : 10 (0 - 9)3) Input power : Single-phase / 3-phase : 200, 220, 230, 240, 380, 400, 415 50/60 Hz

Voltage fluctuation : Within 10% of the rated voltage4) Power consumption : 550 W

(Welt length)

Noise :Workplace-related noise at sewing speedn = 3000 min1 : LPA 83 dB(A)Noise measurement according to DIN 45635-48-B-1.

2

Noise: Workplace-related noise at sewing speedn = 3000 min1 : LPA 83 dB(A)Noise measurement according to DIN 45635-48-B-1.

< APW-298>(1) MECAHNICAL SPECIFICATIONS1) Sewing machine : LH-598 model of 2-needle, lockstitch machine with a center knife and a

needle stop mechanism (exclusively used for APW)2) Sewing speed : 3,000 rpm (max.)3) Stitch length : Lockstitch: 2.0 to 3.4 mm (standard: 2.5mm)

Condensation stitch : 0.5 to 1.5 mm (Standard : 1.0 mm)Back tack stitch : 0.5 to 3.4 mm (Standard : 2.0 mm)Condensation/Back tack stitch selectable

4) Types of welt : Parallel double welt, parallel single welt,slant double welt, slant single welt,trapezoidal stitching

5) Pocket lip length : Possible to set in increments of l mm within the range of 18 mm (min.) to180 mm (max.)Note that the pocket lip length is 25 mm at the minimum when using thecorner knife.For the longer type (option), the maximum sewing length will be 220 mm.

6) Welting width : 10, 12 and 14 mm(needle gauge)

7) Needles : ORGAN DP 17 #16 to #18 (standard #16)SCHMETZ SY3355 #100 to #110 (standard #100)

8) Thread : Spun thread #50 (Recommended)9) Hook : Full rotary, vertical-axis, self-lubrication hook

10) Thread take-up lever : Slide thread take-up lever11) Needle bar stroke : 33.36 mm12) Cloth feed mechanism : Driven by servomotor13) Control : By a micro-computer14) Safety mechanism : Machine operation is automatically stopped if the cloth feed mechanism

error detector and, the needle thread breakage detector or any of the varioussafety devices are actuated.

15) Lubricating oil : JUKI New Defrix Oil No.216) Operating air pressure : 0.5 MPa17) Air consumption : Approx. 40 NR/min.18) Dimensions of the machine : 980 mm (width) 1,650 mm (length) 1,200 mm (height)

(1,580 mm when including the stacker)(1,500 mm when including the thread stand)

19) Weight : Approx. 380 kg

(2) ELECTRICAL SPECIFICATIONSOnce the required data is set by means of a built-in micro-computer, the data can be stored in memory (for100 hours) using a built-in battery even after turning OFF the power to the machine unless the setting iscanceled. In addition, the stored data can be output to a personal computer and saved by making use ofthe exclusive circuit board. Further, these data can be copied to the other machines. Consult our JUKIservice man if necessary.

1) The number of patterns that can be stored in memory : 100 (0 - 99)2) The number of cycles that can be stored in memory : 10 (0 - 9)3) Input power : Single-phase / 3-phase : 200, 220, 230, 240, 380, 400, 415 50/60 Hz

Voltage fluctuation : Within 10% of the rated voltage4) Power consumption : 550 W

Each with flap or without flap

(Welt length)

3

2. NAMES OF COMPONENTSThe machine consists mainly of the following units;A Frame and structural components

(Frame, sewing table, covers, foot switch etc.)B Clamp foot unit and feed mechanismC Corner knife unitD Binder unit (Binder components and its driving components)E Pneumatic control unit (Pneumatic control devices and pipings)F Stacker unitG Sewing machine headH Electric control unit (Control panel)I Oil panJ Operation panelK Power switch

With this machine, you can do desired welting work simply by setting materials (garment body, interliningpiece, welting patch etc.) in place and operating the switches on the operation panel.

E

C

J

G

D

K

A

F

B

4

3. STANDARD ADJUSTMENTS(1) Machine head components1) Main shaft components

1 mm

Standard Adjustment

1 Adjusting the main shaft origin sensorThis sewing machine detects the upper dead point of the needle bar with the main shaft origin sensor1 mounted inside the machine and makes the point the origin to control the revolution of the sewingmachine..... When the power is turned ON, the sewing machine performs the operation of the main shaft origin

retrieval and stops at the upper dead point of the thread take-up lever. In a case where the machinedoes not stop at the upper dead point when the machine is turned by hand pulley or the like, analarm (AL-12 : needle UP trouble) is displayed when the MACHINE READY key is pressed. In thiscase, the machine automatically returns to the upper dead point of the thread take-up lever bypressing the RESET key.(State to perform sewing is obtained.)

Detecting platesetscrew

1

2

3

4

5

Adjustment Procedures Results of Improper Adjustment

1) Turn OFF the power to the machine.2) Loosen the setscrew and remove the top cover (lid located on

the top surface of the sewing machine).3) Turn and stop the sewing machine by hand at the lower dead

point of the needle bar.4) Loosen two collar setscrews 3 and adjust so that detecting

plate 2 is on the operator's side and the edge is vertical.Remove the cap located on the back of the machine head andenter a screwdriver to loosen one of the setscrews.

5) A clearance of 0.5 to 1.5 mm between the detecting plate andthe sensor is the standard adjustment value.If the clearance is not within the specified value, loosen mainshaft origin sensor setscrew 4 to adjust the clearance.

6) When the aforementioned adjustment is completed, attach thetop cover in place and turn ON the power. The adjustment is proper when the sewing machine stops

at the upper dead point of the needle bar.

When the main shaft originsensor and the detecting plateare not properly adjusted, thesewing machine does not stopat the upper dead point of thethread take-up lever.

In case of APW-297, stoppingheight of the needle bar (needletip is 11.5 mm away from thethroat plate) is not within thespecified value, and threadbreakage at the start of sewingmay occur.

6

1 mm

Standard Adjustment

2 Replacing the timing belt

Coupling screw No. 1

Coupling

1

2

3

4

5

4

5

A

7


1) Remove the top cover (lid located on the top surface of thesewing machine).

2) Remove timing belt 2 from lower sprocket wheel 1.3) Enter a hexagonal wrenck key from section A and loosen two

coupling setscrews.4) Loosen the setscrews and remove main shaft motor 3.5) Loosen the setscrews in the upper sprocket wheel asm.6) Loosen the setscrews in the hand pulley gear B.7) Pull out the upper sprocket wheel asm 4.

..... Upper sprocket wheel asm. 4 is pressed in the machinearm. Tap the wheel from the inside of the hole and pull itout toward the left-hand side (b).

8) Pull out the timing belt through the hole.9) Enter a new timing belt and assemble it the same as before.

At this time, be careful of the following matters.* When pressing upper sprocket wheel asm. 4 in the machine

arm, apply the bearing mount (LOCKTITE : 085 for mediumstrength fit) to the wheel.

* The flat sections of both the main shaft and the motor shaftbecome the positions of the coupling screws No. 1.

* Make hand pulley gear B 5 come in contact with the uppersprocket wheel asm 4.

8

bc

aa

c

Standard Adjustment

2) Needle bar components

1 Adjusting the height of the needle bar (APW-297)

2 Adjusting the upper/lower positions of the needle bar frame (APW-298)The respective clearances of the upper and lower positions of the needle bar frame and the needlebar become the values described in the table below.

Portion with * (asterisk) mark : the clearance should be 0.15 m/m or more at the time when pushing upthe needle bar locating at its highest position from the bottom.

Clearance a b cNeedle bar connection2 needles 0.2 m/m or more 0 0.2 m/m or more1 needle 0.2 m/m or more * 0.2 m/m or more

Needle barframe

Upper side marker line isaligned with bottom face of

needle bar frame.

Needle bar : Lower dead point state

Needle barfixed pin

Needle barbracket

At the time of 2 needlesLower bushing

At the time of 1 needle

Needle bar

Needle bar frame

1

2

9


1) To adjust the height of the needle bar, loosen needle bar bracketscrew 1.

2) Turn the hand pulley to bring the needle bar to its lower deadpoint and remove face plate cover 2 of the binder base toadjust the height. Adjust so that the upper marker line engraved on the needle

bar is aligned with the bottom face of the needle bar framewhen the needle bar is in the lower dead point state.

Loosen setscrews 1 and 2 in the needle bar frame shaft baseand turn needle bar frame shaft 3 counterclockwise. Then theneedle bar frame goes up, and clearance "a" becomes smallerand clearance "c" becomes larger.Turn it clockwise and the respective clearances are reversed.(Adjusting area is up to the position where the slot of needle barframe shaft 3 becomes vertical.)After performing the adjustment, tighten setscrews 1 and 2 tofix needle bar frame shaft 3.

Adjustingarea

When the needle bar frame isexcessively high :

Needle bar locking is hard sinceclearance "a" is small, and 1-needle stop failure of slantsewing occurs.(Difference on the sewing endside becomes smaller than thegiven value.)In addition, needle bar lockingfailure occurs at the sewing end.(One stitch drops at the sewingstart of the slant sewing.)

When the needle bar frame isexcessively low :

Needle bar releasing is hardsince clearance "c" is small, and1-needle release failure of slantsewing occurs.(Difference on the sewing startside becomes larger than thegiven value.)

Goes up.

Comes down.

1

2

3

10

Standard Adjustment

1 Needle feed adjusting (cam section)It is normal that the needle feed amount is "0" (zero) when needle feed adjusting motor 1 stops at theorigin..... When the MACHINE READY key is pressed, needle feed adjusting motor 1 performs the origin

retrieval and stops at the origin.

3) Needle feed components

Cover setscrew

Back of thesewing machine

Needle feed originsensor

1

2

3

11


1) Remove needle feed adjusting motor cover 2.2) Turn ON the power and perform the sewing machine

independent operation at 500 rpm under the continuous mode..... At this time, needle feed adjusting motor 1 is excited at the

position of the origin.3) Loosen clamp screw 4 in needle feed adjusting cam 3.4) Turn needle feed adjusting cam 3 while checking the

longitudinal move of the needle bar and tighten clamp screw4 in the cam at the position (angle) where the longitudinalmove stops to fix the cam..... The point of the position (angle) where the longitudinal move

stops is the position where the two cover setscrews comejust below.

(Caution) In addition to the normal installing angle, there isanother angle where the longitudinal move stops.For reference, the longitudinal move becomes "0" (zero)at the angle where the two cover setscrews come justabove. However, the needle feed direction is reverse tothe normal one at this fixing angle when the actual sewingis operated. So, do not adjust to this state.

In the case where the needlefeed amount does not become"0" (zero) when the needle feedadjusting motor stops at theorigin, the needle feed amountin accordance with panel inputvalue (percentage as againstthe sewing pitch) cannot beobtained. Accordingly, theneedle feed cannot be stopped(setting the panel input value to0%).In addition, the needle entryposition in terms of stitches slipsfrom the given entry position.

12

Standard Adjustment

2 Adjusting the installing position of the needle bar frameAdjust the installing position of the needle bar frame so that the needle is in the center of the needlehole (slot) when the needle feed amount is "0" (zero).

1

2

13


* Perform this adjustment after the adjustment of the needle feedadjusting cam described in the previous clause.

1) Turn OFF the power after the needle feed adjusting motor originretrieval operation (turn ON the MACHINE READY key).

2) Turn the hand pulley to lower the needle to the needle hole.3) Remove the top cover (lid located on the top surface of the

sewing machine).4) Loosen clamp screw 2 in needle feed rocking rear arm 1.5) Move the needle bar frame to and fro, position so that the needle

is in the center of the needle hole, and tighten clamp screw 2in needle feed rocking rear arm 1.

When the position of the needlebar frame is not adjusted asdescribed on the left side :Stitches slip from the givenneedle entry position and whenthe adjustment is particularlyimproper, interference of therespective parts occurs. Interference of upper knife

with needle thread trimmerknife

Interference of needle barframe

Interference of needle withneedle hole

14

4 mm 4 mm

Standard Adjustment

3 Adjusting the timing of the needle feed operationAdjust the timing of the needle feed operation so that the timing of the hook catching thread is notslipped even when the needle feed amount is changed..... It is normal that the needle bar does not move to and fro even when turning needle feed adjusting

motor 1 at the timing of alignment of needle and hook (longitudinal move is within 0.5 mm).

Locus of needle feed and needle barThe locus of normal needle feed is as shown in the figures below.The ellipse is increased or reduced in the state that the point of the timing of the hook catching threaddoes not slip longitudinally.

Main shaft

Operator'sside

Top surface ofthroat plate

Timing of hookcatching thread

Operator'sside


Timing of hookcatching thread

1

2

3

15


* Perform this adjustment after the adjustments of the needle feedadjusting cam and the installing position of the needle bar framedescribed in the previous clauses.

1) Turn OFF the power to the machine.2) Turn the hand pulley to align the needle with the hook.3) Remove the top cover.4) Loosen setscrew 2 in the upper knife driving cam.5) Gradually move the angle of upper knife driving cam 3 and

temporarily tighten the cam. Then turn the needle feed adjustingmotor to check the longitudinal move of needle bar.

6) Tighten the setscrew 2 in the upper knife driving cam at theangle where the longitudinal move of needle bar stops to fixthe cam.(Point : The longitudinal move of needle bar stops at the positionwhere letter "S" of the cam faces upward as shown in the figureon the left.).... It is a difficult job and takes time to adjust the cam to the

angle where the longitudinal move of needle bar completelystops.It is no problem functionally if the longitudinal move is within0.5 mm.

When the adjustment of timingof the needle feed is improper,a given locus of needle feedcannot be obtained. As a result,needle feed effect as against thesewing material is lost.

Hook adjusting timing, whenneedle feed amount is changed(when the sewing pitch ischanged or the like), is slippedand sewing conditions will bedeteriorated.

16

Standard Adjustment

4) Needle thread trimmer components


7 0.5 mm

3 0.5 mm

17.5 0.5 mm

27.5 0.5 mm

0.5 mm+0.2 0

1 Adjusting the forward end position of the needle thread trimmer unit

2 Adjusting the lateral position of the needle thread trimmer unit

0.5 mm+0.2 0

1

2

A

3

1

A

17


1) The forward end position of the needle thread trimmer unit iswhere top end A of the moving knife is 3 0.5 mm away fromthe needle and 7 0.5 mm away from the top surface of thethroat plate when knife unit moving cylinder 1 and knife drivingcylinder 2 are in full stroke.

2) Top end A of the moving knife is 17.5 0.5 mm away from theneedle and 27.5 0.5 mm away from the top surface of thethroat plate when knife unit moving cylinder 1 is returned

Loosen two setscrews 3 and perform positioning of the topend of the moving knife for adjustment.

1) For the lateral position of the needle thread trimmer unit, adjustthe center of the needles to the center of the right and leftmoving knives.At this time, the lapping amount of the respective needle centersand the top end of the moving knife is 0.5 mm. (Both rightand left centers)

Loosen two setscrews 1 and adjust the position.

Thread trimming failure occurs. Length of thread remaining from

the fabric is lengthened orshortened.

I n t e r f e r e n c e w i t h o t h e rcomponents occurs.

Thread trimming failure occurs.

+0.2 0

18

Standard Adjustment

3 Adjusting the width of the moving knife of the knife unit

4 Adjusting the fixed knife The fixed knife has to be selected according to the needle gauge. Replace the fixed knife when

changing the needle gauge after delivery.

Needle gauge Dimension10 mm 90.1mm Standard12 mm 110.1mm

14 mm 130.1mm

Needle gauge10 mm

12 mm

14 mm

Selection of typeFixed knife (common to right/left)Fixed knife, left

Fixed knife, rightFixed knife, left

Fixed knife, right

Part No.

25442302

25443102

2544320125443300

25443409

Standard

Center of knifedriving cylinder

9 0.1 mm

Moving knife

Clamp plate

A : 2.9 N or more (300g)

4 mm+0.5 0

12

3

4

5

1

23

4

A

B

19


1) Lateral dimension of the top end of the moving knife is 9 0.1mm. However, this dimension changes according to the needlegauge. Adjust the dimension to the needle gauge.Adjust the distance of the top end of the moving knife usingfour setscrews 1 in the moving knife guide.

(Caution)When performing this adjustment, adjust so that the rightand left moving knives in terms of the center of knife drivingcylinder are set to the same dimension.

2) Projecting amount of the top end of the right/left moving knivesis 4 mm away from the top end of the clamp when themoving knife cylinder has been fully pressed (full stroke).

Loosen nut 2 in the moving knife driving cylinder, turn movingknife driving cylinder rod 3, and move moving knife drivingplate 4 in the direction of the arrow to adjust.

3) Needle thread retaining force should retain spun #60 with 2.9Nor more in the direction A.

Adjust with two screws 5 so that the position of the clampplate is 4 mm from the top end of the moving knife.

Attach the clamp plate so that it is parallel to the moving knife.

1) Fixed knife 2 makes plane A (blade face) of moving knife 1come in close contact with top end section B of fixed knife 2.

Loosen two setscrews 3 in the fixed knife, make plane A ofthe moving knife come in close contact with the top end of thefixed knife, then fix the fixed knife.

(Caution) When adjusting the fixed knife, perform theadjustment with clamp 4 installed.

Thread trimming failure occurs.

Thread trimming failure or clampfailure occurs.

When the retaining force isinsufficient, slip-off of thread atthe sewing start occur

Thread trimming failure or singlethread breakage occurs.

+0.5 0

+0.5 0

20

Standard Adjustment

1 Adjusting the bobbin thread knife

5) Bobbin thread trimmer components

Bobbin thread knife

Throat plate

1 Non-action 2 Action 3 End of action

Operatingdirection

2

134 5

6

7

8

21


1) Position of the bobbin thread knife to the throat plateIn order to prevent the bobbin thread knife from being pinched inthe throat plate while cutting the thread, it is important to set theknife perpendicular to the throat plate.1. Loosen screw 1 and operate bobbin thread knife driving

cylinder 6.2. Set bobbin thread knife bracket 7 so that the knife is not

pinched in the throat plate and firmly tighten screw 1.

2) Position and height of the bobbin thread knifeThe top ends of both left and right knives must be even with thethroat plate surface, and the grooves in the knives must be parallelto the grooves in the throat plate when the knives actuate.1. Loosen screws 2 and adjust so that the top ends of the knives

are even with the throat plate surface.2. Press bobbin thread knife driving cylinder 6 toward A and

adjust so that the grooves in the knives are parallel to thegrooves in the throat plate.

3. Securely tighten screws 2.

3) How to adjust the position of the bobbin thread knife inreplacing gauges

Loosen setscrews 4 and 5 of bobbin thread knife presser plate3, and the bobbin thread knife moves to the right or left togetherwith the bobbin thread knife presser plate.

4) How to replace the bobbin thread knifeLoosen setscrews 2, and you can pull out the knife downward.

5) Adjusting the sharpness of the bobbin thread knifeAdjust the sharpness of the bobbin thread knife, while properlypressing thread grasping presser springs 8 (figure on the left)against the bobbin thread knife.The force with which the springs are pressed against the knifeshould be minimized as far as the knife cuts the thread withoutfail. This helps lengthen the life of the knife.

When the bobbin thread knife islower than the top surface of thethroat plate, bobbin threadtrimming failure occurs.

22

7 mm

5 mm

0.5 mm7 mm

Standard Adjustment

6) Center knife components

Adjust the relevant distances of the center knife as shown in the figure below. Highest dead point of the center knife ...... 5 mm above the surface side of the throat plate Lowest dead point of the center knife ....... 0.5 mm above the surface side of the throat plate

Surface side of the arm

1 How to adjust the height of the center knife 2 How to adjust the distance from theneedle to the center knife

3 Adjusting the sharpness of the center knife

4 Attaching the center knife

Needle

Throat platesurface

Fixed knife

1

2

3

4

A

23


1 How to adjust the height of the center knifeLoosen screw A and adjust so that a 5 mm clearance is obtainedwhen the center knife comes to its highest dead point by raisingor lowering the center knife.When tightening the screw, be careful not to provide it with a lateralplay.

2 How to adjust the distance from the needle to the centerknife

Loosen screw 1 and correctly adjust the position of the centerknife by moving it forward or backward.

3 Adjusting the sharpness of the center knifeThe sharpness of the center knife is adjusted by pressing the sideface of the center knife to the blade section of the fixed knife ofthe throat plate.Move the center knife laterally by screw 2 or rotate it by screw 3to obtain the suitable pressing force.Be sure to adjust the pressing force as light as possible so thatthe center knife completely cuts the two plies of the fabric used.

4 Attaching and removing the center knife Removing the center knifeLoosen screws 4, and remove the center knife.Tighten screws 4, and attach the center knife. At this time, pushthe center knife to the base until it will go no further and fix at thatposition.

24

0.2 to 0.3 mm

0 to 0.05 mm

0 to 0.05 mm

4 m

m0.

8 m

m

Standard Adjustment

7) Hook components

1 Adjusting the timing of the hook to the needle 2 Adjusting the timing of the hook

3 Adjusting the clearance between the needle and the hook blade point

4 Removing and attaching the hooks Removing the hooks 1 Remove the throat plate.

2 Remove the bobbin case opening lever.3 Loosen three setscrews 2 in the small gear of the hook shaft.4 Turn the handwheel until the needle bar is raised to its highest position

and take out the hooks. Attaching the hooks 1 Reverse the above procedures.

2 Turn by hand the bobbin case holder until its projection rests in the grooveon the throat plate and fix the throat plate.

5 Adjusting the bobbin case opening lever

Hook blade point

Needle

1

2

A

B

C

A

B

C

3

4

5

25


1 Adjusting the timing of the hook to the needle Remove the throat plate. When the needle has gone up 4 mm from its lowest point. adjust

the position of the hook so that the blade points of left/righthooks align with the center of the needle. At this time, adjustso that the clearance between the side face of the needle andneedle guard 1 of the hook is 0 to -0.05 mm, that the clearancebetween the side face of the needle and the blade point is 0 to0.05 mm and that the distance between the top end of theneedle hole and the hook blade point is 0.8 mm.

2 Adjusting the timing of the hook Loosen three setscrews 2 in the small gear of the hook shaft.

Manually turn the hook to make the hook blade point align withthe center of the needle. Then tighten setscrews 2 whilepressing the hook downwards and the gear upwards in orderto eliminate a vertical play of the hook shaft.

3 Adjusting the clearance between the needle and the hookblade point

Remove the throat plate and tilt the machine backwards. Loosen screws A and B in the hook driving shaft saddle located

on the machine side to be adjusted. Lightly tap hook driving shaft saddle C, and move it to the left

or right until the clearance between the needle and the bladepoint of the hook is adjusted to 0 to -0.05 mm. Then firmlytighten screws A. In addition, moderately tighten screws B.

(Caution) Screw B is fixed holding the hook driving shaftbushing. If it is tightened excessively, the turning torqueof the hook driving shaft will be increased. So, be carefulnot to tighten it excessively.

5 Adjusting the bobbin case opening lever Turn the handwheel by hand in the regular direction to let bobbin

case opening lever 4 withdraw to the end of its stroke in thedirection of arrow and make sure that there is a clearance of0.2 to 0.3 mm between the bobbin case opening lever andprojection 5 of the bobbin case (turn the bobbin case in thedirection of arrow and hold it in place by hand).This can be adjusted by loosening screw 3 in the bobbin caseopening lever.

26

28 mm

Standard Adjustment

8) Wiper components

Standard Adjustment

1 Adjusting the injector for the reflux of the face plate components Reflux of the face plate components is performed

with injector 1 installed on the bottom side of themachine bed.

The standard value of the reflux amount isobtained at the position where the injectoradjustment screw 2 is turned back four times fromits fully screwed state.

Adjusting the amount of oil in the hook Appropriate amount of oil in the hook is obtained when a sheet of

paper is placed approximately 1 cm away from the hook, operatethe sewing machine for 10 seconds, and oil splashes stick to thepaper at the height of the hook blade point as shown in the figure.

Min. Max.

A

B

1 Adjusting the wiper

9) Lubrication components

1

1

23

1

cd

27



1) Tilt the machine head.2) Loosen nut 3 and move screw 2 in the direction of the arrow

to adjust the injector. Moving the screw in the direction A strengthens the injector

and the reflux amount is increased. Moving the screw in the direction B weakens the injector and

the reflux amount is decreased.

1) Perform the adjustment of the amount of oil with screw 1 inthe outer hook.Turning clockwise decreases the amount of oil and turning itcounterclockwise increases the amount of oil.

Oil may drop from the bottom ofthe face plate.

Adjust the wiper with clamp screw 1 so that the dimension ofclearance between the bottom end of the wiper and the face plateof the machine head is 28 mm when the cylinder is actuated.

If the wiper operating amount issmall, slip-off of thread at thesewing start occurs.

If the wiper operating amount islarge, defective stitch tightness atthe sewing start occurs.

28

0.2 N

9 mm

Standard Adjustment

10) Thread tension components

1 Adjusting the thread take-up spring

2 Adjusting the timing of the thread tension disc to start "floating"

Adjusting nut

7 to 8 mm

1

2

34

5

6

7

8

9

29


1 Adjusting the thread take-up spring For adjusting the tension of the left needle thread take-up spring,

loosen screw 1 and turn 2. Turning 2 clockwise will increasethe tension of the left needle thread take-up spring, orcounterclockwise will decrease it.For adjusting the tension of the right needle thread take-upspring, loosen screw 3 and turn 4. Turning 4 clockwise willincrease the tension of the right needle thread take-up spring,or counterclockwise will decrease it.For adjusting the stroke of the left needle thread take-up spring,loosen screw 5, and turn 6.Turn 6 clockwise to increase the stroke of the left needle threadtake-up spring or counterclockwise to decrease it.Adjust the stroke of the right needle thread take-up spring inthe same procedure as mentioned above.Standard adjustment value

Stroke : 7 to 8 mmSpring pressure : 0.2N

2 Adjusting the timing of the thread tension disc to start"floating"

Adjust disc floating joint 8 so that both the left and the righttension discs start to float simultaneously when thread tensiondisc releasing cylinder 7 has actuated.Adjust the floating distance within the range from 1.0 to 1.5mm.

The standard value of the clearance between the disc floatingjoint 8 and the thread tension bracket plate 9 is 9 mm. (Whenthe cylinder does not actuate.)

30

a Adjustment of torsion b Lateral adjustment

c Adjustment of inclination

Standard Adjustment

(2) Device components1) Binder components

1 Front binder

Front binder

Garment bodyclamp

a

b

c d

1

2

3

4

5

6

7

8

9

!0

31

a Adjustment of torsion1) The difference (parallelism) of the clearance between the

garment body clamp and the front binder (welt patch ruler)should be within 0.2 mm when the top end of the garmentbody clamp has moved from position a to that of b.

When the aforementioned dimension is not obtained, loosensetscrew 1, loosen two nuts 2, and adjust the torsion of thefront binder while pressing two setscrews 3 on base 4.

(Caution)When setscrew 1 is loosened, the front binder falls down.Push upward (in the direction of the arrow) base 4 whentightening setscrew 1.

b Lateral adjustment1) Check the needle entry position (dimensions c and d in the

figure should be laterally equal.). When the dimensions c and d are different from each other,

loosen screw 7 and nut 5, and move binder !0 to the right orleft.

The stopper in the lateral direction of the binder is adjustedwith screw 6.

Slightly loosen nut 8 and screw 9 when the binder cannot belaterally adjusted.

(Caution)The inclination of the front binder changes when 8 and 9are loosened. Adjust the inclination referring to cAdjustment of inclination.

c Adjustment of inclination1) In the state that the front binder rides on the welt patch ruller

with the power OFF, loosen screws 7 and 9, and nut 8, andperform adjustment of the parallelism of the front binder.

1

4


If the parallel move is notobtained, the front and rear weltpatch widths become uneven.

If c and d are not equal, thedifference of right and left weltpatch widths is caused.

32

1 Front binder

d Adjustment of longitudinal position

f Adjustment of material guide

3 mm

1 mm 2 mm

Standard Adjustment

0.5 to 1 mm

Needle entryposition

10.5 to 11 mm

Joint

23 to 24 mm

Top surface ofsewing table

e Adjustment of height

The heights of topsurfaces of welt patchrulers should be equal.

Stopper

1

2

3

3

4

5

6

7

8

9

!0

!1

33


d Adjustment of longitudinal position1) Loosen screws 1 and adjust so that the distance from the

needle entry position to the top end of the welt patch ruler is10.5 to 11 mm.

(Caution)Check that the knife cover section of binder base doesnot interfere with the center knife.

e Adjustment of height1) Turn ON the power, loosen the setscrew of the stopper, and

adjust the height so that the distance from the top surface ofthe sewing table to the bottom face of the welt patch ruler is 23to 24 mm when the binder goes up.

2) Loosen nut 2 at the top end of the cylinder, and adjust so thata clearance of 3 mm is provided between the cylinder joint andthe pin when the binder comes down (with the power OFF).

3) Lift front binder 3, loosen nut 7, turn stopper bolt 4 and adjustso that the heights of the rulers should be equal when theheights of the top surfaces of the welt patch rulers of frontbinder 3 and rear binder 6 are not equal at the position wherestopper bolt 4 comes in contact with binder stopper 5.

f Adjustment of material guide1) Clearance between the top surface of welt patch ruler when it

is pressed and lowered by the material guide spring and thebottom face of the material guide is 1 mm.

2) Clearance between the material guide and the welt patch ruleris 2 mm when the material guide goes up.

3) Loosen nuts 8 and adjust the clearance with bolts 9 whenthe material guide comes down.

4) Clearance between the material guide and the needle in thelateral direction is 0.2 to 0.5 mm at the part of the shank (thickpart of the needle).

5) Loosen screw !0 to adjust the clearance.6) Adjust the pressing pressure of the material guide with screw

!1.

If the heights of the front and therear rulers are not equal, weltpatch or interlining may be indanger of being caught in thejoint of the ruler at the time ofjump feed after start.In addition, garment materialmay be in danger of beingcaught in the joint of the ruler.

34

Standard Adjustment

2 Rear binder

a Adjustment of inclination and longitudinal adjustment

b Adjustment of torsion

To be 0

3 to 4 mm

1

2

3

4

5

2

35


a Adjustment of inclination and longitudinal adjustment1) Loosen four setscrews 2 and perform the adjustment of

inclination of rear binder 3. Tighten setscrews 2 so that thebottom face of the welt patch ruler and the top surface of sewingtable 4 should be parallel when the power is turned OFF.At the same time, tighten setscrews 2 so that the clearancebetween rear binder 3 and the front binder is 3 to 4 mm.

(Caution)When four setscrews 1 in the binder bracket are loosened,not only the inclination of rear binder but also that of alldevices mounted on the binder such as front binder, flapfeeding unit, etc. will change.Do not loosen the setscrews unless the adjustment ofinclination of the whole devices is performed.

b Adjustment of torsion1) The rear binder is required to be set straight as against the

front binder.2) Loosen screws 5 to adjust the direction of torsion of the rear

binder as against the front binder which has completed theparallel adjustment in terms of the moving direction of the clampfoot.

Torsion of the rear bindercauses the unevenness of left/right and front/rear of the weltpatch.

36

2.5 mm12 mm

Standard Adjustment

2 Rear binder

c Lateral adjustment

d Adjustment of height

e Adjustment of welt patch clamp needle

1 to 1.5 mm

14 mm

1

2

3

4

5

6

37


c Lateral adjustment1) It is necessary that the rear binder is installed in the way that it

has no slip in the lateral direction as against the front binderwhich has completed the adjustment of the needle entryposition.

2) When the rear binder slips in the lateral direction as againstthe front binder, loosen bolt 2 in the binder oscillating stopperand adjust the slip by moving in and out stopper 1.

3) Check that the bottom face of welt patch ruler 3 and the topsurface of sewing table 4 are parallel as viewed from theoperators side.

d Adjustment of height1) Adjust the clearance between the bottom face of the welt patch

ruler and the top surface of the sewing table to 1 to 1.5 mmwhen the rear binder is coming down by the up-and-downcylinder.

2) When the clearance is not obtained, loosen lock nut 5 in theup-and-down cylinder to adjust the clearance.

3) When the power is turned ON, the distance from the top surfaceof the table from the bottom face of the ruler is 110.5 mm(reference), and the clearance between the top surface of thetable and the welt patch holding dish is 14 mm (reference).

e Adjustment of welt patch clamp needle1) The welt patch clamp needle in the rear binder is drawn back

from the welt patch ruler when the power is turned ON.2) Protruding amount from the welt patch ruler to the top end of

the needle is 2.5 mm when the welt patch is clamped.3) To adjust the protruding amount of the needle, loosen lock nut

6 in the welt patch clamp needle drive cylinder and adjust theamount.The standard dimension is 12 mm when the needle is drawnback.

4) Check that there is no longitudinal play in terms of the wholeneedle including the cylinder when the needle comes out. Ifthere is a play, loosen cylinder lock nut 6 and make thedimension of 12 mm larger.

(Caution) However, the needle should not come out abovethe welt patch ruler in the state that the needle is drawnback.

When the rear binder slips in thelateral direction, there is adanger that interlining or weltpatch is caught with the jointsection of the front or rearb inde r . I n add i t i on , t heunevenness of left/right weltpatch widths is caused.

If the needle comes out abovethe welt patch ruler, welt patchclamp failure due to the bluntneedle or slippage of interliningor welt patch at the time of jumpfeed during sewing is caused.

38

8.2

mm 9.8 2N

3 to 4N

2.1 mm

Standard Adjustment

2) Clamp foot components

1 Adjusting the tension of the clamp foot traveling belt

2 Adjusting the tension of the clamp foot driving belt

Drivingpulley

Longslot

Drivenpulley

1

2

3

39


The tension of the clamp foot traveling belt can be adjusted byloosening lock nut 1 and shifting the driven pulley along thelong slot. (The pulley can be shifted by moving adjusting screw2 back and forth.)The tension on the belt should be adjusted so that the middleof the belt slackens by approximately 8.2 mm when a pressureof 9.8 2 N is applied.After making the adjustment, securely tighten lock nut 1.

The tension of the clamp foot driving belt can be adjusted byloosening setscrew 3 and moving the whole of motor bracket upand down.The tension on the belt should be adjusted so that the middle ofthe belt slackens by approximately 2.1 mm when a pressure of 3to 4N is applied.After making the adjustment, securely tighten setscrew 3.

If the tension is excessively low,variation of sewing position orknife position is caused.

If the tension is excessively low,variation of sewing position orknife position is caused.

40

70 mm8 mm

225 mm 355 mm

320 mm 35 mm

Standard Adjustment

3 Clamp foot front end stop position and rear end stop position

For rear end stop

Photosensor

Detectorplate

Standard distances for photosensor location

Center of the needle

For front end detector

Rear endstop position

Garment clamp

Front endstop position

Garment clamp

Slit section

1

2

3

41


Clamp foot front end stop position and rear end stop positionare to be determined by the position of the photosensors.Determine the stop position of the clamp foot as shown in thefigure referring to the standard distances for photosensors.Clamp foot front end is where tip of the garment clamp is 355mm away from the center of the needle.Clamp foot rear end is where tip of the garment clamp is 225mm away from the center of the needle.

Set detector plate 3 so that it is positioned approximately inthe center of photosensor 2 slit section.When the position is not made as mentioned above, loosenphotosensor bracket setscrew 1 and adjust the position bymoving photosensor 2 to the right or left.

42

4 Adjusting the garment clamp lifting amount

5 Adjusting the welt patch folding plate and the flap presser

Aba

20 to 22 mm

Standard Adjustment

Clamp footcylinder bracket Garment clamp

A B = 0.2 mm or less

Garmentclamp (left)

Garmentclamp (right)

1.5 mm

16 mm1 to 1.5 mm 1 to 1.5 mm

Sewing table

1

2

3

A

B

1

2

34

5

6

2

1

3

43


4 Adjusting the garment clamp lifting amount The garment clamp, after the power is turned ON, goes up by

means of the air cylinder.The standard lifting amount of the garment clamp is 20 to 22mm from the surface side of the sewing table measured at thetip of it. Adjust the lifting amount by loosening setscrew 1 inthe clamp foot cylinder bracket, and move the whole of the aircylinder up or down.

The clearance between A - B must be kept in parallel to thewelt patch base plate. Make sure that the difference betweenthe front and rear ends of each garment clamp must not exceed0.2 mm.If the clearance is not kept in parallel, loosen screws 2, andmove the garment clamp in the direction of arrow using thewelt patch base plate as reference.

Loosen screws 3 and adjust so that the clearance betweenthe garment clamp and the welt patch base plate should be0.8 to 1.3 mm.

Standard overlapping width of folding plate 3 with welt patchbase plate 4 is 1 to 1.5 mm.

To adjust the overlapping amount, loosen setscrew 1 and movefolding plate 3 properly.

The standard position of flap presser 6 is where the top endcomes out by 1.5 mm from the folding plate rubber 5 (therubber is pasted at the position which is 16 mm away from thetop end of the folding plate).

To adjust the position of flap presser 6, loosen setscrews 2and move flap presser 6 properly.

44

Standard Adjustment

3) Corner knife components

1 Corner knife mechanism of APW-297

[Operation of the corner knife]Turn corner knife travel motor a ON, and moving corner knife b (sewing start position) will travel tothe position which has been predetermined in accordance with the length to be sewn.At the travel end position, the moving corner knife and fixed corner knife c (sewing end position) willbe raised by each exclusive lifting air cylinders d and e, and cut a material.

[Corner knife cutting position]

Origin detector plate

Moving corner knifeorigin detectionphotoswitch

A

G

320 mm

355 mm

35 mm

Sewing start corner knife position

Garment clamp Garment clamp

Sewing end corner knife position

Center ofthe needle

G Gauge (mm) 10 12 14A Dimensions after assembled (mm) 129.9 127.4 124.4

a

b c

d e

45


When the desired dimension cannot be obtained, loosensetscrew f to adjust the dimension.

f

46

3 mm

25 mm

3.5 mm

Standard Adjustment

Adjusting the clearance between fixed corner knife and moving corner knife

Adjusting the height of the corner knife

Moving corner knife Fixed corner knife

Table

Knife guide

a

b

c

d

A

1

2

47


Provide a clearance A of 3 mm between the fixed corner knifeand the moving corner knife at the position of the origin asshown in the figure. The position of the origin of the movingcorner knife is detected at the moment when the corner knifereturns to its origin after having travelled. The corner knife stopsafter having travelled 25 mm from the point where photoswitcha detected detector plate b. At that time, clearance a is 3mm. Adjust the moving corner knife by sliding switch attachingbracket d after loosening setscrew c.

When the corner knife lifting cylinder reaches its lowest position,there must be a clearance of approximate 3.5 mm betweenthe top ends of both moving corner knife and fixed corner knifeand the surface side of the table as shown in the figure. Thisadjustment can be made by loosening lock nut 1 and turningadjust nut 2.

48

A

G

320 mm

355 mm

35 mm

Standard Adjustment

2 Corner knife mechanism of APW-298

[Operation of the corner knife]Turn corner knife travel motor a ON, and moving corner knife b (sewing start position) will travel tothe position which has been predetermined in accordance with the length to be sewn.At the travel end position, the moving corner knife and fixed corner knife c (sewing end position) willbe raised by each exclusive lifting air cylinders d and e and cut a material.

[Corner knife cutting position]

Turret rotationmotor

Origin detector plate

Moving corner knifeorigin detection

Turret lock detection

Sewing start cornerknife position

Garment clamp Garment clamp

Sewing end corner knife position

Center ofthe needle

G Gauge (mm) 10 12 14A Dimensions after assembled (mm) 200 196.3 192.5

a

b c

de

49

f


When the desired dimension cannot be obtained, loosensetscrew f to adjust the dimension.

50

3 mm

25 mm

7.7 mm

Standard Adjustment

Adjusting the clearance between fixed corner knife and moving corner knife

Adjusting the height of the corner knife

Moving corner knife Fixed corner knife

Moving corner knife

Table

Knife guide

Fixed corner knife

Corner knifelifting cylinder

a

bc

d

1

2

1

2

A

51


Provide a clearance A of 3 mm between the fixed corner knifeand the moving corner knife at the position of the origin asshown in the figure. The position of the origin of the movingknife is detected at the moment when the corner knife returnsto its origin after having travelled. The corner knife stops afterhaving travelled 25 mm from the point where photoswitch adetected detector plate b. At that time, clearance A is 3 mm.Adjust the moving corner knife by sliding switch attachingbracket d after loosening setscrew c.

When the corner knife lifting cylinder reaches its lowest position,there must be a clearance of 7.7 mm between the top ends ofboth moving corner knife and fixed corner knife and the surfaceside of the table as shown in the figure. This adjustment canbe made by loosening lock nut 1 to adjust the screwing amountand moving the whole lifting rods 2 up or down.

52

1

1.5 0.5 mm

Standard Adjustment

3 How to set the corner knife on the knife base wheel

Detector plate

Free

Free2

1

34

5

6

7Set as desired

Open

Difference 0

Difference 0

Difference2 mm

Difference2 mm

Difference2 mm

Difference2 mm

Turret lock detector plate

Figure observedby an operator

Direction ofrotation

FreeFree

Right 2 mm

Left 2 mm

2

1

34

5

6

7

53


Loosen setscrew 1 and adjust the turret lock proximity switchso that a clearance of 1.5 0.5 mm is provided between theswitch and the detector plate.

54

0.3 to 0.5 mm

Standard Adjustment

0.3 to 0.5 mm

0.3 to 0.5 mm

4 Adjusting the center of the corner knife

5 Adjusting the deflection and distortion of the corner knife

6 Adjusting the knife

Deflection of 0.15 mm per travellingdistance of 300 mm

Deflection of 0 0.5 mm per travellingdistance of 180 mm

Clamp foot travelling path

Travelling distanceof 180 mmCorner knife travelling path

Needle

Center ofthe needle

Not good Good

Seam

55


The center of the corner knife should be aligned with the center ofthe needle when the corner knife moves. Although the alignmentis correctly adjusted at the time of delivery, in the event that thecorner knife bracket is moved due to an external impact, loosenthe bolt fixing the corner knife frame in place, and shake the wholecorner knife bracket so that the clearance between the movingcorner knife and the center of the needle is 0 0.5 mm or lesswhen the moving corner knife is moved approximately 180 mm.When adjusting the clearance by moving the corner knife bracket,be sure to loosen the setscrew in the fixed bracket supporting theopposite side of the shaft.

If the corner knife is attached with deflected to right or left, ordistorted, defective state of the cut part may result as illustratedin the figure on the left.The corner knife should always cut the center of the seamsand should not cut the thread in the seam. Once the center ofthe corner knife has been correctly adjusted, only a fineadjustment will be required to attach a corner knife blade.

When replacing or adjusting the corner knife, first move the clampfoot to its backward travel end using the CLAMP FOOT TRAVELkey on the operation panel, and secondly remove the sewing tableand operate the corner knife elevating solenoid valve by hand toallow the corner knife to go up. Then take the below-stated stepsof procedure.After the adjustment, carry out thorough-going tests to confirmthat no faulty cut product is finished. Then start the sewing work.

56

Standard Adjustment

7 Adjusting the corner knife for parallel sewing

8 Fine adjustment of corner knife in terms of seams

Approx. 4.5 mm

Groove in theknife holder

Tip of the cornerknife blade

G ... Needle gauge

G

1

2

3

3

4

5

6

7

57


The following description explains the adjusting method for thecorner knife for parallel sewing which is the standard type ofsewing.

1) Adjust the opening amount of corner knife holders 1 in thefigure on the left to 4.5 mm and temporarily tighten screw 2.

2) Insert the corner knife into the groove in the corner knife holderas shown in the figure on the left. Position the corner knife sothat the distance almost same as the needle gauge is providedbetween the tips of blades. Then fix the knife there by turningeccentric pin 3 in the direction of the arrow.This temporarily fixes the corner knife. Then perform a trialstitching using the material to be sewn in the actual sewing,and finely adjust the installing position of the corner knife sothat the notch matching the seam is obtained.

1) Loosen eccentric pin 3 shown in the figure given at the top ofthe previous page, and adjust the cutting length 6 shown inthe figure at the bottom of the previous page by moving thecorner knife in the direction of arrow 4.

(Caution) When moving the corner knife, top end 5 of theknife should be covered.

2) Loosen screws 2 shown in the figure at the top of the previouspage, and adjust the angle of notch 7 shown in the figure atthe top of the previous page by changing the opening amountof the corner knife holders.

58

A

B

e

e

A

B

Standard Adjustment

9 Adjusting the corner knife for slant sewing When using the corner knife in the slant sewing with a difference, adjust the corner knife following

the instructions described below, based on the aforementioned temporarily fixed position of thecorner knife for parallel sewing.

As an example, the adjusting procedure of corner knife adapting to the following sewing pattern isdescribed.

Sewing start difference ... A

Sewing end difference ... B

Parallel sewing state Slant sewing state

Make the blade protrude from the standard position bynarrowing the angle of corner knife 2.

Parallel sewing state Slant sewing state

1

2

3

4

1

2

34

2

3

59


1) To adjust the corner knife to sewing start difference A, cornerknife blade 1 on the left-hand side should be kept in the parallelsewing state as illustrated in the sketch on the left, and cornerknife blade 2 should be moved to extend the cutting length inaccordance with the difference as illustrated in the sketch onthe right. (Follow the procedure same as that described on thenext page.)

2) The corner knife is adjusted to rear difference B in the similarmanner. Only corner knife blade 3 should be moved to extendthe cutting length in accordance with the sewing end difference.After the completion of the adjustment, finely adjust knife blades1, 2, 3 and 4 in accordance with the seam in the proceduresama as that described on the next page.The corner knife can be adjusted by extending the cutting lengthof the longer seam regardless of the kinds of slant sewing.

60

(OK) (NG)

a

7 to 8 mm

1 mm

Standard Adjustment

(3) Optional components1) Welt patch cut unit (right) : SA102

Welt patch receiverplate asm.

Welt patch whose front and rear sides are cutshould be aligned with the cutting position ofthe center knife.

Figure (a)

Welt patch cut presser

The lifting positon of the welt patch cut knife is where theblade end of the knife is lower 1 mm from the top surface ofsponge rubber.

* Expel the air with the finger valve located in the rear of thepower switch, loosen screw 3, and pull out the knife upwardto replace the knife.(Be careful of the direction of the knife blade.)

* The blade section is on the left-hand side as observedfrom the front.

1

2

3

4

5

61


The centers of welt patch holding plate asm. and binder asm.should be aligned with each other. Welt patch cut knife in termsof welt patch clamp needles should be positioned in the center.)e If not, loosen screw 1 to adjust the position of welt patch

holding plate.1) Make the welt patch clamp needles appear in the state of the

binder with swung and set the binder lifting cylinder to air-freestate.

2) Lift the binder by hand and make the welt patch cut knife appear.Then checking with the naked eye the clearance between theknife and the welt patch clamp needles at the longitudinalposition of the knife, adjust the clearance.(Figure (a)) < Perform the aforementioned checking byoperating the solenoid valve by hand.>

(Caution) Perform the aforementioned adjustment afteradjusting the welt patch width.

Welt patch cut presser Welt patch cut presser should be positioned 7 to 8 mm away

from the welt patch receiver plate. Welt patch cut knife should be positioned in the center of

groove of the welt patch cut presser. When the welt patch is pressed by the welt patch cut presser,

the pressing pressure should be equal longitudinally andlaterally.

1) Adjust the vertical position and longitudinal pressing pressureof the welt patch cut presser by loosening two screws 2.

2) Adjust the lateral direction of the welt patch cut presser byloosening two screws 4.

3) Adjust the protruding amount by loosening nut 5 at the topend of the cylinder and turning the cylinder rod.

If the cutting position of front andrear of the welt patch is not inthe center, the unevenness ofleft/right welt patch widths iscaused. Further, in the worsecase, welt patch supply failureis caused.

If the pressing pressure isuneven, welt patch cut failure oroccurrence of smallwrinkle atthe time of welt patch cut iscaused.

If the protruding amount of theknife is excessively large, weltpatch cut failure is caused.

62

8 mm

11 mm

1 to 1.5 mm

0.5 to 1 mm

Standard Adjustment

Lifting amount of the welt patch cut presser shouldbe 8 mm from the welt patch receiver plate.

Position of the welt patch cut presser should be11 mm from the edge of the welt patch receiverplate.

Clearance between the detector plate and originsensor 5 is 1 to 1.5 mm.Sensor should be turned ON in the state that thesensor travel base travels to the operator's sideuntil it will go no further and collides with knife travelbase (B).

Single welt and double welt changeover switch

The switch should protrude 0.5 to 1 mm from thetop surface of the welt patch receiver plate.

1

2

3

4

5

63


Adjust the lifting amount by loosening nut 4 and turning thecylinder rod.

Adjust the position by loosening two screws 1.

Adjust the clearance and position of the origin sensor 5 byloosening two screws 2.

Adjust the vertical position of the single welt and double weltchangeover switch by loosening screw 3.

When this switch is pressed withthe single welt stopper, theoperation of the cutting knife offront and rear of the welt patchis stopped.

When the single welt stopper isprovided, if the cutting knife offront and rear of the welt patchoperates, the knife interfereswith the stopper and the knifebreakage is caused.

64

35 to 36 mm

54 mm

5 to 6 mm

135 mm

12.5 to 13.5 mm

3 to 4 mm

1.5 to 2.5 mm

Standard Adjustment

2) Flap supply unit (left) : SA103

Clamp click

Binder


1

2

3

4

5

6

7

8

9

!0

!1

!1

65


1) Adjust with stopper 1 the clearance (3 to 4 mm) in the heightdirection between the clamp click and the binder when the clampclick comes down.

2) Adjust with stopper 2 the vertical travel amount of the flapsupply unit.

3) Adjust the clearance (12.5 to 13.5 mm) between the clampclick and the sewing table by loosening screws 5 and !0.(To be equal in the longitudinal direction)

4) Adjust with stopper 3 the clearance between the side face ofthe binder and the clamp click when the clamp click comesdown.

5) Loosen nut 4 in the oscillating cylinder and adjust the height(135 mm) of the clamp click from the top surface of the sewingtable when the clamp click returnes to the position of the receiverplate.

6) Adjust the clamping pressure of the clamp click by looseningscrews 5.

7) Adjust the parallel of the clamp click to the sewing table byloosening screws 6.

8) Adjust the angle of flap receiver plate !1 by loosening screw 7.Adjust the longitudinal inclination of the flap receiver plate !1by loosening two screws 8.Adjust the clearance (5 to 6 mm) between the flap receiverplate !1 and the clamp click by loosening two screws 9.

If the clearance between theclamp click and the sewing tableis excessively small, the clampclick interferes with the flappresser or the rubber on thefolding plate.

If the clearance between theclamp click and the sewing tableis excessively large, there is adanger that the finished size ofthe flap varies.

66

15.8 mm

Standard Adjustment

Press the flap presser uniformly.

Align the flap presser with the edge of theholding dish to install it.

3) Flap and bag cloth supply unit (left) : SA104

Origin slit should be positioned 15.8 mmfrom the flap receiver plate.

Origin slit

Flap presser arm

Flap presser arm and presser arm driving cylinderdo not interfere with each other, and should movesmoothly.

Flappresser

Holding dish

58.9 mm(Reference value)

1

2

3

4

5

6

78

67


Adjust the position of the origin slit by loosening screw 5. The flap sensor should move in parallel to the holding dish

when the flap sensor moves longitudinally. Loosen screws 3 and 4 to adjust the flap sensor.

The flap sensor should move smoothly without any play. Loosen screw 1 and 2 to adjust the flap sensor.

If it does not move smoothly, loosen screw 6 and adjust theposition and angle of the cylinder.

Adjust the pressing pressure of the flap presser by looseningscrew 7.

Adjust the longitudinal position of the flap presser by looseningscrew 8.

68

4.7

mm

0.52 N

f

Standard Adjustment

(a) Adjustment of the sensor slit Position of the origin slit 1 is 15.8 0.3 mm away from holding dish 2.

(b) Adjustment of belt tension

15.8 0.3 mm

1 2

3

4

5

69


(a) Adjustment of sensor slitLoosen setscrew 3 and adjust origin slit 1.

(b) Adjustment of belt tension1) Loosen four setscrews 4 in the motor, draw motor 5 in the

direction of the arrow f to stretch the belt.2) Apply a 0.52N load to the center of the belt and confirm that

the belt sags 4.7 mm.

I f the bel t is excessivelystretched, the service life of thebelt is deteriorated or drivingtorque will be caused.

If the belt is insufficientlystretched, tooth skipping will becaused.

70

(58.9 mm)

Standard Adjustment

(c) Adjustment of flap presser Distance from flap presser arm 1 to the edge of holding dish 2 is (58.9 mm). (Reference value)

In addition, install so that flap presser arm 1 and the edge of holding dish 2 should be almostparallel.

Pressure on the top end side of flap presser 3 is low and the flap presser is installed slightlyslantingly.

Top end

Top end3

4

1

2

3

4

5

6

7

8

9

3

71


1) Loosen two setscrews 7 in the flap presser rotating base toadjust the flap presser.

Note) At this time, check that flap presser cylinder 8 movessmoothly. (Expel air from the cylinder to check.)

2) Loosen two setscrews 6 in the flap presser base, move flappresser base 5 in the direction of the arrow, and adjust so thatflap presser 3 is aligned with the edge of holding dish 4.

3) Loosen two setscrews 9 in the flap presser and install flappresser 3 slightly slantingly to increase the pressure on thetop end side of flap presser 3.

Flap is not pressed or flap mayslip at the time of delivery of flap.

72

AB

Standard Adjustment

(d) Adjustment of flap holding dish

5 to 6 mm

To come inclose contact

377.5 0.5 mm from the center of needleNeedle

1

2

3

4 5

6

1

2

73


1) Loosen two setscrews 3 in the flap holding dish and adjust sothat the clearance between flap holding dish 1 and clamp nail2 is 5 to 6 mm and so that the edge A of flap holding dish 1 isparallel to the edge B of clamp nail 2.

2) Loosen two setscrew 6 and adjust the flap holding dish to377.5 0.5 mm away from the center of the needle. (At thistime, make holding plate fitting shaft 4 come in close contactwith shaft base 5.)

When the clamp nail is not inparallel to the flap holding dish,the flap is sewn slantingly.

The sewing position of the flapin the lateral direction may slip.

74

135 mm

89 mm

4) Dart extending unit : SA106

CN36 connector

CN43connector

Center ofthe needle



Assembling procedure

Control box

1

2

3

6

7

8

5

6

7

8

9

!0

13

4

!1

!0

75

Connect dart extending cylinder 2 to connecting plate 1 withthe screws as shown.

Install the solenoid valve for dart extending 5 with the screwsat the second place from the right side of the upper manifoldwhile inserting a packing between the valve and manifold.

PipingConnect the air tubes of 4, green 6 and yellow 7, located onthe side of dart extending cylinder to the joint of the solenoid valve. WiringConnect the connector of the dart upper detection sensor 8 toCN36 located on MAIN circuit board 9.Insert the pins of the solenoid valve cable !0 into No. 45, +24Vand No. 46, Dart output of the connector CN43.

1. Position of the dart extendingDetermine the center at the positon of 135 mm from the centerof the needle.If the 135 mm is not obtained, loosen screws 4 in connectingplate 1 to adjust the position.The presser of the dart extending should press the upper partof the center of the needle.Adjust the lateral direction by loosening screw 3.

2. Loosen nut !1 and adjust the height of the dart extending sothat it is 89 mm from the top surface of the sewing table.

When the screw is excessivelytightened, malfunction of thecylinder is caused.

Assembling procedure Caution when assembling

76

5) Suction unit : SA108

Packing (2)Packing (1)

Control box

CN73 : Vacuum output OUT-71

For vacuum


1

2

3

6

7

4

5

6

7

AB

A

B

77

Attach suction plate 1 together with packings (1) and (2) inthe rear of the main body frame with screws (spring washersand nuts). 5 places

Attach duct attching base 2 to main body frame 3 with screws.(spring washer and nut).

Replace the sewing table with the one for vacuum.

Attach the solenoid valve to the solenoid valve base. Connect the solenoid valve cable 4 to CN73 connector on I/O

circuit board 5 inside the control box. Connect the air tubes, 4 Yellow 6 and 4 Green 7 of the air

cylinder for valve drive to the solenoid valve.


78

6) Interlining feeding unit : SA109

Control box

CN71 connector

CN68 connector


6Tube

6 TubeFinger valve

Solenoid valveSteppingmotor

1

2

3

4

5

6

9

7

8

9

79

Attach the interlining feeding unit body from the top surface ofthe table with screws 1 and nuts 2 (3 places). (In this case,place a spacer 3 between the body frame and the interliningfeeding unit and fix the unit. In case of the machine with thevacuum unit, the spacer is not necessary.)

Piping Connect 6 Blue tube 4 to the solenoid valve from the air

supply tube of the solenoid valve located at the power switchbracket section located under the right-hand bottom of the table.Connect 4 Yellow 5 and 4 Green 6 tubes to the cylinderfor scissors drive.

Wiring Insert +24V cable of solenoid valve cable for scissors drive 7

to No. 35 of CN68 connector on I/O circuit board 8 inside thecontrol box and insert the output cable to No. 36 of CN68connector.

Insert automatic interlining feeding cable 9 of the steppingmotor for interlining feeding to CN71 connector on I/O circuitboard 8.


80

Standard Adjustment

Interlining feeding unit

Interlining

0.8 to 1.2 mm

1.5 to 2 mm

Moving knife 0.3 to 0.5 mm

0.8 to 1.2 mm

1 to 1.5 mm

Moving knife

Guide (D)

Guide (C)

8

9!0

2

3

4

8

9

!0

5

67

81


1) Position of guide A !0 in terms of fixed knife 8 should be 0.3 to0.5 mm away from the blade point and 1.5 to 2 mm away fromthe top surface of the blade. When the position is not obtained,loosen screws 2 to adjust the position.

2) Top end of guide B 9 should be in the position of 0.8 to 1.2mm from the bottom face of fixed knife 8. When the position isnot obtained, loosen screw 3 to adjust the position.

3) Guide A !0 and guide B 9 should be parallel and perpendiculareach other. If they are not parallel, adjust them by looseningscrew 3.

4) Provide a clearance of 1 to 1.5 mm between guide A !0 andguide B 9. If not, adjust it by loosening screw 3.

5) Length of engagement of scissors on the fixed side and that onthe moving side shoud be 0.8 to 1.2 mm at the top end.

6) Loosen screw 4 and adjust pressing pressure of guide B 9so that it is equal at the left end and right end of the interliningfeeding roller.

7) Rolled interlining should be fed to the center through the slotsection of the table.Loosen screws 5, 6 and 7 for fixing guide to adjust the guidein accordance with the width of the interlining.

8) Adjusting the interlining guide positionIt is necessary to adjust so that the guide (D) is positioned inthe center of the slot of the sewing table and that the height isaligned with the table surface.Loosen setscrew A to adjust the longitudinal position andsetscrew B to adjust the height.

Guide (D)

A

B

Sewing table

Guide (C)

82

7) Single welt and double welt change unit (right) : SA111

Set collar

Set collar


!1

!2

5

6

7

8 9

!0

1

2

34

6

!0

1

2

3

4

!2

!3

1

!3

83

Attach finger valve 6 to the fulcrum base 5 with the screws. Attach cylinder stay 7 to fulcrum base 5 with the screws. Connect cylinder stay 7 to air cylinder 8 with the pin. Assemble rod end 9 to cylinder 8. Attach rod end 9 to clamp foot arm (right) !0 with the screw. Attach air operate valve !2 to solenoid valve base (1) !1 with

the screws.

Air piping Branch 6 tube !3 from the regulator, and connect one of 4

black tube 1 to air operate valve !2 and the other to fingervalve 6.

Connect 4 pink tube 2 from finger valve 6, 4 blue tube 3and 4 transparent tube 4 from air cylinder 8 to air operatevalve !2 via the rear of the clamp foot.

Clamp foot arm (right) !0 should move to the left or right (ba)by the air cylinder 8 when finger valve 6 is changed over.

Adjust the position of the set collar so that it is the position ofthe double welt when the clamp foot arm is on the left and thatit is the position of the single welt when the clamp foot arm ison the right.


84

8) Clamp bar stacker : SP44

Connectingplace

Stacker unit

Double-sideadhesive tape


1

2

3

4

56

7

8

9

!0

!1

!2

9

85

Attach hinge attaching plate 1 to the left side face of the bodyframe with four pcs. each of screw 2, spring washer 3 andflat washer 4.

Attach two connecting blocks 5 to the left side face of thebody frame with two pcs. each of screw 6.

Peel off the paper on the double-side adhesive tape on therubber cushion and paste rubber cushion !0 to connecting block5. (2 places)

Attach pipe support (1) 7 and pipe support (2) 8 with setscrews9.

Put the whole stacker on the hinge to set it. Connect the connector on the stacker side to connector A !1.

Connect the air source from the joint at the top of the regulator.

Perform piping to the pipe for air blow and fix it with setscrew!2.


86

Standard Adjustment

Clamp bar stacker : SP44

Cloth presser bars (1) 5 and (2) 6 should uniformlypress cloth holder base 7.In addition, the relation between cloth presser bar (1)5 and that (2) 6 in terms of cloth holder base 7should be as shown in the figure.(Bars (1) and (2) do not interfere with each other.)When cloth presser bar (2) 6 is released, it shouldnot come in contact with left side cover !2.

When the clamp bar stacker is in the standby state,the relation between cloth brush bar 8 and clothpresser bar (1) 5 should be as shown in the figure.

Position of the cloth placing base

32 mm

Sub table

10 mm

120 mm

86 mm

180 mm

11mm

Cloth placingbase

1234

5

6

7

8

5

6

7

!2

5 8

9

!2

5

8

!0

!1

!2

87


Adjust the inclination and the protruding amount of cloth presserbar (1) 5 by loosening screw 1.

Adjust the inclination and the protruding amount of cloth presserbar (2) 6 by loosening screw 2.

Adjust the stroke of cloth presser bar (2) 6 by loosening screw3.

Adjust the position of cloth brush bar 8 by loosening nut 4.

Adjust the dimension 180 mm from left side cover !2 to thecloth placing base by loosening nut 9.

Adjust the positions of cloth presser bar (1) 5 and cloth brushbar 8 by loosening nuts !0 and !1.

88

4. OPERATION PANEL(1) Operating the operation changeover screen

Turn ON 2 of the DIP switch (DSW1) located on the side of the panel, and press 1 of the numerickeys, while holding pressing key. Then the screen moves to the operation selection screen.

Each operation can be changed in this screen. Pictograph No. is displayed above each pictograph.

Data contained in < > change when key is pressed.

< DB >

[ DF ]Alphabet D means that this screen is the operation selection screen.

Alphabet in this section means the pictograph No. (A to G)Data contained in [ ] do not change even when key is pressed.

* Setting of binder self-holding operation changeover *

: Self-holding of operation of clamp foot and binder is not performed.

: Self-holding of operation of clamp foot and binder is performed.Press the RESET button to release this setting.Standard operation

* Setting of back tack stitching operation changeover *

: Standard operation(The sewing machine temporarily stops at the time of back tack stitchingoperation.)

: The sewing machine dose not stop and continues to sew in the back tackstitching.

* Setting of folding plate release at the time of corner knife operation *

: Folding plate is closed and flap presser continues to be closed at the time ofcorner knife operation.

: This setting returns the folding plate and opens the flap presser at the time ofcorner knife operation.

Standard operation

* Setting of binder oscillating operation changeover *

: Automatic welt patch feeding unit operates.Standard operation

: Automatic welt patch feeding unit stops.(Binder does not oscillate.)

89

[DE]

7 0 0

1 0 0 0

[DF]

[DG]

* Setting of starting speed at the sewing start *

Data setting commendable value : 500 rpm(Data range : 500 to 2,500 rpm)

Setting data (input with the numeric keys)

* Setting of speed of 2nd stitch at the sewing start *

Data setting commendable value : 700 rpm(Data range : 500 to 2,500 rpm)


* Setting of speed of 3rd stitch at the sewing start *

Data setting commendable value : 1,000 rpm(Data range : 500 to 2,500 rpm)


(2) Check program 8Status of the batch of sensors is displayed in this screen.1) Pressing adjustment data edit screen key, press 0 of the numeric keys, and pictograph No. [

CP ] CHECK PROGRAM is displayed in the operation display section.2) Press 8 of the numeric keys, then press key to start CHECK PROGRAM mode = 8. At this time,

the screen below is displayed.

Press R key to end the check program and the screen returns to the standard one.(Caution) IN67 to 96 are for reserves.

0 1 2 3 4 5 6 7 8 9IN0 IN1 IN2

IN3 IN4 IN5

IN6 IN7

IN8 IN9

CHECK PROGRAM : ON : OFF

KEY = RETURN

5 0 0

90

(3) Initial setting tableThe initial value of each data is as given below when the power is turned ON.

1) * Operation mode changeover *: Cloth feed mode (at this time, tension disk is closed.)

* Sewing mode changeover *: L-size sewing

* Sewing reference changeover *: Rear-reference sewing (The sewing end position is spaced 320 mm away from

the needle bar.)

* Changeover of operation/stop of the automatic flap feeding unit *: Setting of the automatic flap feeding unit operation

* Changeover of operation/stop of the stacker operation *: Setting of the stacker operation

* Changeover of the welt patch cutting device operation *: Setting of the welt patch cutting device operation

* Flap jump speed setting *: Flap jump speed (unit : mm/s)

* Setting of flap concealed stitching data *: Flap concealed stitching data for the sewing start of left-hand side seam (seam

is produced outside the flap.)

* Setting of flap concealed stitching data *: Flap concealed stitching data for the sewing end of left-hand side seam (seam

is produced outside the flap.)

* Setting of flap forced stop data *: Flap forced stop

0

[AG]

[AL]

2 5 0

0. 0

5

0. 0

91

* Corner knife selection *: Corner knife selection

* Setting of difference at the sewing start *: Difference at the sewing start (The right-hand side seam is shorter than the left-

hand side one.)* The pictograph appears on the display only for APW-298. For the APW-297, it

will not appear on the display.

* Setting of difference at the sewing end *: Difference at the sewing end (The left-hand side seam is shorter than the right-

hand side one.)* The pictograph appears on the display only for APW-298. For the APW-297, it

will not appear on the display.

* Setting of the center knife actuating position at the sewing start *: Center knife actuating position at the sewing start

* Setting of the center knife actuating position at the sewing end *: Center knife actuating position at the sewing end

* Setting of the corner knife actuating position at the sewing start *: Corner knife actuating position at the sewing start (The knife retracts.)

* Corner knife actuating position at the sewing end *: Corner knife actuating position at the sewing end (The knife retracts.)

* Lockstitch pitch setting *: Lockstitch pitch

* Setting of condensation stitching and back tack stitching at the sewingstart *

: Setting of condensation stitching and condensation pitch at the sewing start

[AM]

[AP]

[AQ]

[AT]

1

0

0

1 2

1 2

0 . 0

0 . 0

2 . 5

1 . 0

92

* Setting of the number of back tack stitches at the sewing start *: Setting of the number of back tack stitches at the sewing start

* Setting of condensation stitching and back tack stitching at the sewing end *: Setting of condensation stitching and condensation pitch at the sewing end

* Setting of the number of back tack stitches at the sewing end *: Setting of the number of back tack stitches at the sewing end

* Dart stretcher operation changeover *: Dart stretcher is set to operative.

* Vacuum operation changeover *: Vacuum is set to operative.

* Changing over the operation of the automatic interlining cloth feeder *: Automatic interlining cloth feeder is set to operative.

2) * Total counter *

* No. of pcs. counter *

* Bobbin thread counter *

* Setting of the actuation of the bobbin thread remaining amount detectingdevice and the bobbin thread remaining amount adjusting counter *

[AV]

[AX]

[BA]

[BB]

[BC]

3

1 . 0

3

0

0

0

0

93

3)

[CF]

[CG]

[CH]

0 . 1 0

1 . 5 0

6 0

* Changeover of the clamp foot position after completion of sewing *: Back end stopping mode

* Changeover of operation/stop of optional dart stretcher*: Dart stretcher operates.

* Changeover of operation/stop of optional vacuum *: Vacuum operates.

* Setting of the speed of the automatic interlining cloth feeder *: Low speed* The pictograph appears on the display only when the automatic interlining cloth

feeder is mounted.

* Excess length of interlining cloth to be fed by the automatic interliningcloth feeder (at the start of sewing) *

* The pictograph appears on the display only when the automatic interlining clothfeeder is mounted.

* Excess length of interlining cloth to be fed by the automatic interliningcloth feeder (at the end of sewing) *

* The pictograph appears on the display only when the automatic interlining clothfeeder is mounted.

* Welt patch sensor detecting time *: Stop

* Setting of thread trimming timing *: Timer of the thread trimmer (standard timing)

* Setting of the stacker timer 1 *: Stacker timer 1 (unit : second)

* Setting of the stacker timer 2 *: Stacker timer 2 (unit : second)

* Setting of needle throwing ratio for the normal feed section *: Needle throwing ratio for the normal feed section(The needle throws in direction same as that of the feed.)

15

15

[Cb]

[Cc]

94

[CK]

[CL]

[CN]

[CO]

[CP]

3 0 0 0

1 5 0 0

2 . 0 0

2 . 0 0

0

* Setting of needle throwing ratio for the back tack stitching at the sewingstart *

: Needle throwing ratio for the back tack stitching at the sewing start(The needle rocks in the opposite direction of the feed.)

* Setting of needle throwing ratio for the back tack stitching at the sewingend *

: Needle throwing ratio for the back tack stitching at the sewing end(The needle throws in direction same as that of the feed.)

* Setting of sewing speed under the high-speed mode *: Number of revolutions for lockstitching

* Setting of sewing speed under the low-speed mode *: Setting of the sewing speed for condensation stitching or backtacking

* Setting of the sewing machine independent operation mode *: The sewing machine independent operation mode starts up using the DIP

switches.: No operation

* Setting of ON time of the intermittent operation of the sewing machinunder the independent sewing mode *

* Setting of OFF time of the intermittent operation of the sewing machineunder the independent sewing mode *

* Check program mode selection *

* Front reference position changeover *: Front reference position is spaced 140 mm away from the needle position.

* Display mode changeover *: Cycle mode

[CI]

[CJ]

6 0

6 0

95

4) * Setting of binder self-holding operation changeover *: Standard operation

* Setting of back tack stitching operation changeover *: Standard operation

* Setting of folding plate release when the corner knife actuates. *: Standard operation

* Seting of binder oscillating operation changeover *: Standard operation

* Setting of starting speed at the sewing start *:

Partsbook Juki APW-297&298 EM

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Transcript of Partsbook Juki APW-297&298 EM